David O. Kazmer, P.E., Ph.D.
Specializing in plastic product design and polymer process development.

Simulation

Overview

At the heart of every decision is an understanding of the relationship between the decision variables to the expected outcomes. Since such knowledge is so significant in product design and manufacturing process development, phenomenological simulation and numerical analysis is a continuous activity. The act of developing these simulations provides significant insight into the process physics, and the results are very useful for integrated product and process design.

Past Advances

Advanced Molding Simulations

Over the past decade, we have developed multiple process simulations for injection molding, thermoforming, blow molding, and extrusion. The scope and capability of the analyses varies widely by application. Our most sophisticated simulation is a thermoviscoelastic, compressible, molding simulation that permits modeling of composite thermal mold structures with arbitrary initial and boundary conditions. As shown in the figures below, this simulation has been used for development of dynamic mold heating/cooling processes, molding of optical media, and others to predict bulk temperature, injection pressure, shear stress, residual stress, warpage, birefringence, and other part properties.

Current Research

3D Dynamic Polymer Flows

Currently, our research is focusing on the modeling of flows in machine elements including a low force valve, a self-regulating pressure valve, a polymer lubricated hydrodynamic bearing, other geometries. Shown below is a picture of velocity vectors flowing through a self-regulating melt valve. This simulation allows us to understand the pressure drops, shear rates, and flow through the valve and to maximize performance with improved designs.

Faster Than Real Time Process Simulation

We have also developed and are continuing to develop and validate very fast simulations for incorporation into real time process controllers. The two figures are main effects plot showing the observed and predicted part weights for a variety of process conditions. It is observed that the simulation very well captures the main effects but has some variances. It is hoped that in the future this approach can reduce the need for trial and error setups or lengthy design of experiments, and assist in debugging processes and achieving optimal processes.

Multi-Scale Polymer Annealing

We are developing a a multi-scale, polymer annealing simulation to predict the development of polymer morphology on the nano scale. The goal is to guide the development of nanco-scale templates and molding of copolymers to develop complex structures in three dimensions.

Related Publications

  1. Kazmer, D.O., “Injection Molding,” Encyclopedia of Chemical Processing, Marcel Dekker, Sunggyu (K.B.) Lee, Ed., 2005.

  2. Kazmer, D.O., “Computer Flow Simulations,” Society of Plastics Engineers’ Molding Toolbox, 2002.

  3. Kazmer, D. O., "Development and Validation of a Radial Flow Analysis Tool", M.S.E. Thesis, Department of Mechanical Engineering, Rensselaer Polytechnic Institute, 1991.

  4. D. O. Kazmer, R. Nageri, V. Kudchakar, B. Fan., R. X. Gao, “Validation of Three On-Line Flow Simulations for Injection Molding,” Submitted to Polymer Engineering and Science.

  5. S. Johnston and D. Kazmer, “Decoupled Gating and Simulation for Injection Molding,” Submitted to International Polymer Processing.

  6. Y. Cui, R. X. Gao, and D. O. Kazmer, “A Bond Graph Approach to Energy Efficiency Analysis of a Self-Powered Wireless Pressure Sensor,” Submitted to Journal of Smart Structures and Systems.

  7. Kazmer, D., and B. Fan, “Polymer Flow in a Melt Pressure Regulator,” Submitted to the ASME Journal of Manufacturing Science.

  8. B. Fan, D. Kazmer, and R. Nageri, “An Analytical Non-Newtonian and Non-Isothermal Viscous Flow Simulation,” Submitted to Polymer Plastics Technology and Engineering.

  9. B. Fan,  D. O. Kazmer, W.C. Bushko, R. P. Thierault, A. J. Poslinski, “Birefringence Prediction of Optical Media,” Polymer Engineering & Science, v. 44, n. 4, April, 2004, p. 814-824.

  10. B. Fan and D. O. Kazmer, “Simulation of Injection-Compression Molding of Optical Media,” Polymer Engineering & Science, v. 43, n. 3, p. 596-606, 2003.

  11. Kazmer, D., L. Zhu, and D. Hatch, “Process Window Derivation With an Application to Optical Media Manufacturing,” ASME Journal of Manufacturing Science, v. 123, p. 303-314, 2001.

  12. H. Xu and D. Kazmer, “Thermoforming Shrinkage Prediction,” Journal of Polymer Engineering and Science, v. 41, n. 9, 2001.

  13. D. Hatch and D. Kazmer “Process Transfer Function Development For Optical Media Manufacturing,” International Journal of Advanced Manufacturing Technology, v. 18, n. 4, 2001.

  14. H. Xu, J. Wysocki, D. Kazmer, P. Bristow, B. Landa, J. Riello, C. Messina, and R. Marrey, “Shrinkage Estimation for Thermoformed Parts,” Thermoforming Quarterly, March, 2000, p. 8-14.

  15. Xu, H. and D. O. Kazmer, “A Stiffness-Based Criterion for Ejection of Injection Molded Parts,” International Journal of Polymer Processing, 1999. 14 (1), p. 52-60.

  16. Petrova, T. and D.O. Kazmer, “Incorporation of Phenomenological Models in a Hybrid Network for Quality Control of Injection Molding,” Polymer-Plastics Technology and Engineering, 1999. 38 (1), p. 1-18.

  17. Petrova, T. and D.O. Kazmer, “Hybrid Neural Networks for Pressure Control of Injection Molding,” Advances in Polymer Technology, 1999. 18 (1), p. 19-31.

  18. Taylor, C.A., H.G. DeLorenzi, and D.O. Kazmer, “Experimental and Numerical Investigations of the Thermoforming Process,” Polymer Engineering and Science, 1992. 32(16): p. 1163-1173.

  19. David O. Kazmer, Ranjan Nageri, Bingfeng Fan, Vijay Kudchadkar, Stephen Johnston, "Validation of On-Line Molding Process Simulation," Proceedings of the 2005 Society of Plastics Engineers Annual Technical Conference, 2005.

  20. David O. Kazmer, Kathryn Garnavish, & Ranjan Nageri, "An Investigation into Hesitation Effects in Oscillating Flows," Proceedings of the 2005 Society of Plastics Engineers Annual Technical Conference, 2005.

  21. D. Kazmer, B. Fan, R. Mukhari, "Real Time Flow Rate Estimation in Injection Molding," Molding Technology Symposium at the 20th Annual Meeting of the Polymer Processing Society, Akron, OH, June 21, 2003.

  22. D. Kazmer, and B. Fan, "Simulation of Polymer Flow in a Dynamic Pressure Regulator," 8th International Conference on Numerical Methods in Manufacturing Processes, American Institute of Physics, June, 2004.

  23. Kazmer, D., B. Fan, and R. Najeri, "On-Line Flow Rate and Pressure Analysis with Sensor Fusion," 2004 Society of Plastics Engineers Annual Technical Conference: Injection Molding Division, Chicago, IL.

  24. D. Kazmer, “Synthesis of Melt Pumps and Brakes for Polymer Processing,” National Science Foundation Design & Manufacturing Conference, 2004.

  25. Fan, B. and D. Kazmer (2003), “Simulation of Optical Media Molding,” Society of Plastics Engineers Annual Technical Conference: Injection Molding Division, Nashville, TN. 

  26. Fan, B., Hatch, D., and D. O. Kazmer, “Simulation Based Optimization of Injection Molding,” International Polymer Processing Society, May 2001. 

  27. Ambady, P. and D. O. Kazmer, “Model Predictive Control of Injection Molding,” Society of Plastics Engineers Annual Technical Conference, May 2001. Dallas, TX. 

  28. Bernier, M. Doyle, D. Kazmer, and T. Powell, “Shear Rates in Dynamic Feed,” Proceeding of the Plastics Odyssey, SPE Regional Technical Conference, 2001, Rochester, NY. 

  29. P. Ambady, B. Fan, D. Hatch, and D. Kazmer, “Process Design For Optimal Mold Cooling,” Proceedings of Materials Processing Symposium of the ASME International Mechanical Engineering Congress & Exposition, 2000. 

  30. Xu, H., J. Wysocki, , D. O. Kazmer, P. Bristow, B. Landa, J. Riello, C. Messina, and R. Marrey, “Shrinkage Prediction of Thermoformed Part.” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1999. New York, NY. 

  31. Xu, H. and D. O. Kazmer, “A Study of Cooling for Steady-State Injection Molding.” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1999. New York, NY. 

  32. Hatch, D., D. O. Kazmer, and M. Niemeyer, “Transfer Function Development for Injection Molding of Optical Media.” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1999. New York, NY. 

  33. Poslinski, A., Fox, C., Kazmer, D., “Correlation Of Spiral And Radial Flow Lengths For Injection-Molded Thermoplastics,” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1998. Atlanta, GA. 

  34. Petrova, T., Kazmer, D. O., “Development of a Hybrid Neural Network for Quality Control of Injection Molding,” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1998. Atlanta, GA. 

  35. Kazmer, D. O., Petrova, T., “Analysis and Synthesis of Methods for Intelligent Processing of Polymeric Materials,” Proceedings of the Polymer Processing Symposium, ASME International Mechanical Exposition, 1997. 

  36. Kazmer, D. O., Rowland, J. R., “The Challenges of Intelligent Process Control”, Proceedings of the International Polymer Processing Symposium, 1997.

  37. Burke, C. T., Kazmer, D. O., “Experimental Comparison of State of the Art High Shear Rate Polymer Rheological Characterization Techniques,” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1993.

  38. Irani, R. I., Kodiyalam, S., Kazmer, D. O., “Runner System Balancing for Injection Molds using Approximation Concepts and Numerical Optimization,” Proceeding from the 18th Annual ASME Design Automation Conference, 1992. 

  39. Burke, C. T., Kazmer, D. O., “An Experimental Validation of a Shrinkage/Warpage Predictor,” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1992. 

  40. DiScipio, W. R., Kazmer, D. O., “Validation of Radial-Filling Simulation Software,” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1992. 

  41. Kazmer, D. O., Willey, S. J., “Examination of Material Characterization and Modeling Techniques for Injection Molding Simulation,” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1992. 

  42. Kazmer, D. O., “Simulation of the Blow Molding and Thermoforming Processes,” Proceedings of the International Industrial Engineering Conference, p. 269-275, Chicago, IL, May 17-20, 1992. 

  43. Taylor, C. A., DeLorenzi, H. G., Kazmer, D. O., “Experimental and Numerical Investigations of the Thermoforming Process,” Proceedings from the American Society of Mechanical Engineers Winter Annual Meeting, 1991. 

  44. Kazmer, D. O., “Application of an Axisymmetric Element for Injection Molding Analysis,” Proceedings from the Society of Plastics Engineers Regional Technical Conference, Boston, MA, 1990. 

  45. D. Kazmer, “Advanced Methods for Plastic Product Design and Process Control,” Toyota Motor and Suppliers Meeting, Lowell, MA, April 22, 2005.

  46. D. Kazmer, “Simulation of Polymer Processing,” National Science Foundation Center for High Rate Nano-Manufacturing, Lowell, MA, March 26th, 2005.

  47. Kazmer, D. O., “CAE & Polymer Processing Monitoring & Control: A Design Perspective,” 2001 Gordon Conference on CAE in Polymer Processing, March 2001. Ventura, CA. 

  48. D. Kazmer, “Fundamentals of Polymer Processing,” Proceedings of the Annual Technical Meeting of the Society of Plastics Engineers, Orlando, FL, 2000. 

  49. Kazmer, D. O., “Synthesis and Analysis of Quality Control Methods for Intelligent Processing of Polymeric Materials,” Canada National Research Center, Montreal, Quebec, February 2000. 

  50. Kazmer, D. O., Rowland, J. R., “The Challenges of Intelligent Process Control”, Proceedings of the International Polymer Processing Exposition, 1997.

  51. D. Kazmer, Technical Report to MoldMasters Ltd., “Technical Feasibility of Advanced Molding Technnologies: On-Line Flow Simulation, Digital Valve Modulation, and Self Regulating Valves,” 490 pages, 2004.

  52. D. Kazmer, Invention Disclosure, Sensor Fusion for Deriving Flow Rates and Pressures in Injection Molding, 2003.

  53. Kazmer, D. O., “Evaluation of Advanced Simulations for the Injection Molding Process,” GE Plastics Internal Report, Pittsfield, MA, 1992.

  54. Kazmer, D. O., "Diskflow Validation Summary," GE Plastics Report, 1992. 

  55. Kazmer, D. O., "Customer Training Manual on Mold Packing Analysis," GE Plastics Report, 1992. 

  56. Kazmer, D. O., “Development of a Radial Flow Analysis for Injection Molding,” GE Research & Development Technical Information Series Number 91CRD195, 1991. 

  57. Kazmer, D. O., “Adaptive Meshing of Two-Dimensional Evolving Geometries,” GE Research & Development Technical Information Series Number 90CRD198, 1990.